Composite handle for tools

Abstract

An implement handle includes an axially elongated core member having a varying cross-sectional outer dimension, and an outer polymeric shell having axially-oriented substantially-continuous strength members, the outer shell enclosing and being bonded to the core and of substantially uniform thickness. The handle may include a wood core and a bendable portion integral with the shell, the bendable portion being adapted to fit within a handle socket of a tool.

What is claimed is: 
     
       1. An implement handle, comprising: an axially elongated polymeric shell having an axial centerline and a closed and hollow cross-sectional shape of predetermined inner and outer dimensions wherein both the inner and outer dimensions vary along the axial length of the shell, said dimensional variation including several dimensional reversals comprising positive and negative changes in the inner and outer dimensions with respect to the axial centerline, whereby a complex tapered shape is formed;   substantially-continuous axially-oriented reinforcing fibers embedded in the shell; and   a core member fully enclosed within said shell, the core member having outer dimensions which conform to the inner dimensions of said shell.   
     
     
       2. The handle as claimed in claim 1, wherein the shell is bonded to the core. 
     
     
       3. The handle as claimed in claim 2, wherein the core has a solid cross-section. 
     
     
       4. The handle as claimed in claim 3, wherein the core is wood. 
     
     
       5. The handle as claimed in claim 1, wherein the core is foam. 
     
     
       6. The handle as claimed in claim 1, wherein the core is a honeycomb structure. 
     
     
       7. The handle as claimed in claim 1, wherein the cross-section of the shell is substantially circular. 
     
     
       8. The handle as claimed in claim 2, wherein the shell comprises: at least one layer of resin-impregnated fiber-reinforced material extending along at least a portion of the length of the handle; and   a veil layer including resin-impregnated fabric, an outer surface of which forms the outer dimensions of the shell.   
     
     
       9. The handle as claimed in claim 8, including at least one layer of resin-impregnated fiber-reinforced material extending substantially the entire axial length of the handle and an additional layer of resin impregnated reinforced material extending a limited portion of the axial length of the handle. 
     
     
       10. The handle as claimed in claim 8, wherein the veil layer comprises a polyester fabric. 
     
     
       11. The handle as claimed in claim 8, further including a coating layer covering the veil layer. 
     
     
       12. The handle as claimed in claim 1, wherein the material of outer shell and reinforcing fibers are selected so that the stiffness and yield strength of the shell is greater than that of the core. 
     
     
       13. The handle as claimed in claim 1, further comprising a bendable end portion integral with the shell, the bendable end portion being more bendable than the shell and adapted to fit within a handle socket of a tool. 
     
     
       14. The handle as claimed in claim 13, wherein said bendable end portion is configured such that a first and second series of projections extend generally normal to the length of the bendable end portion and wherein the first series of projections are alternately spaced with the second series of projections along the length of said end portion. 
     
     
       15. The handle as claimed in claim 1, wherein the shell has a substantially uniform cross-sectional thickness throughout its axial length. 
     
     
       16. An implement handle, comprising: an axially elongated core member having an axial centerline and varying cross-sectional outer dimensions, said varying cross-sectional outer dimensions including several dimensional reversals comprising positive and negative changes in the outer dimensions; and   an outer polymeric shell having axially-oriented substantially-continuous strength members, the outer shell fully enclosing and bonded to the core and being of substantially uniform thickness.